RAID 5 re-add of removed drive? (failed drive replacement)

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I have a serious RAID problem here. Please have a look at this. Any help
would be greatly appreciated!

As always, most problems occur only during critical tasks like
enlarging/restoring. I tried to replace a drive in my 7disc 6T RAID5 array
as explained here:
http://michael-prokop.at/blog/2006/09/09/raid5-online-resizing-with-linux/

After removing a drive and restoring to the new one, another disc in the
array failed. Now I still have all the data redundantly available (the old
drive is still there), but the RAID header is now in a state where it's
impossible to access the data. Is it possible to rearrange the drives to
force the kernel to a valid array?

Here is the story:

// my normal boot log showing RAID devices

Jun  1 22:37:45 localhost klogd: md: md0 stopped.
Jun  1 22:37:45 localhost klogd: md: bind<sdl1>
Jun  1 22:37:45 localhost klogd: md: bind<sdh1>
Jun  1 22:37:45 localhost klogd: md: bind<sdj1>
Jun  1 22:37:45 localhost klogd: md: bind<sdk1>
Jun  1 22:37:45 localhost klogd: md: bind<sdg1>
Jun  1 22:37:45 localhost klogd: md: bind<sda1>
Jun  1 22:37:45 localhost klogd: md: bind<sdi1>
Jun  1 22:37:45 localhost klogd: xor: automatically using best checksumming
function: generic_sse
Jun  1 22:37:45 localhost klogd:    generic_sse:  5144.000 MB/sec
Jun  1 22:37:45 localhost klogd: xor: using function: generic_sse (5144.000
MB/sec)
Jun  1 22:37:45 localhost klogd: async_tx: api initialized (async)
Jun  1 22:37:45 localhost klogd: raid6: int64x1   1539 MB/s
Jun  1 22:37:45 localhost klogd: raid6: int64x2   1558 MB/s
Jun  1 22:37:45 localhost klogd: raid6: int64x4   1968 MB/s
Jun  1 22:37:45 localhost klogd: raid6: int64x8   1554 MB/s
Jun  1 22:37:45 localhost klogd: raid6: sse2x1    2441 MB/s
Jun  1 22:37:45 localhost klogd: raid6: sse2x2    3250 MB/s
Jun  1 22:37:45 localhost klogd: raid6: sse2x4    3460 MB/s
Jun  1 22:37:45 localhost klogd: raid6: using algorithm sse2x4 (3460 MB/s)
Jun  1 22:37:45 localhost klogd: md: raid6 personality registered for level
6
Jun  1 22:37:45 localhost klogd: md: raid5 personality registered for level
5
Jun  1 22:37:45 localhost klogd: md: raid4 personality registered for level
4
Jun  1 22:37:45 localhost klogd: raid5: device sdi1 operational as raid disk
0
Jun  1 22:37:45 localhost klogd: raid5: device sda1 operational as raid disk
6
Jun  1 22:37:45 localhost klogd: raid5: device sdg1 operational as raid disk
5
Jun  1 22:37:45 localhost klogd: raid5: device sdk1 operational as raid disk
4
Jun  1 22:37:45 localhost klogd: raid5: device sdj1 operational as raid disk
3
Jun  1 22:37:45 localhost klogd: raid5: device sdh1 operational as raid disk
2
Jun  1 22:37:45 localhost klogd: raid5: device sdl1 operational as raid disk
1
Jun  1 22:37:45 localhost klogd: raid5: allocated 7434kB for md0
Jun  1 22:37:45 localhost klogd: raid5: raid level 5 set md0 active with 7
out of 7 devices, algorithm 2
Jun  1 22:37:45 localhost klogd: RAID5 conf printout:
Jun  1 22:37:45 localhost klogd:  --- rd:7 wd:7
Jun  1 22:37:45 localhost klogd:  disk 0, o:1, dev:sdi1
Jun  1 22:37:45 localhost klogd:  disk 1, o:1, dev:sdl1
Jun  1 22:37:45 localhost klogd:  disk 2, o:1, dev:sdh1
Jun  1 22:37:45 localhost klogd:  disk 3, o:1, dev:sdj1
Jun  1 22:37:45 localhost klogd:  disk 4, o:1, dev:sdk1
Jun  1 22:37:45 localhost klogd:  disk 5, o:1, dev:sdg1
Jun  1 22:37:45 localhost klogd:  disk 6, o:1, dev:sda1
Jun  1 22:37:45 localhost klogd: md0: detected capacity change from 0 to
6001213046784
Jun  1 22:37:45 localhost klogd:  md0: unknown partition table

// now a new spare drive is added

[root@localhost ~]# mdadm /dev/md0 --add /dev/sdb1

Jun  1 22:42:00 localhost klogd: md: bind<sdb1>

// and here goes the drive replacement

[root@localhost ~]# mdadm /dev/md0 --fail /dev/sdi1 --remove /dev/sdi1

Jun  1 22:44:10 localhost klogd: raid5: Disk failure on sdi1, disabling
device.
Jun  1 22:44:10 localhost klogd: raid5: Operation continuing on 6 devices.
Jun  1 22:44:10 localhost klogd: RAID5 conf printout:
Jun  1 22:44:10 localhost klogd:  --- rd:7 wd:6
Jun  1 22:44:10 localhost klogd:  disk 0, o:0, dev:sdi1
Jun  1 22:44:10 localhost klogd:  disk 1, o:1, dev:sdl1
Jun  1 22:44:10 localhost klogd:  disk 2, o:1, dev:sdh1
Jun  1 22:44:10 localhost klogd:  disk 3, o:1, dev:sdj1
Jun  1 22:44:10 localhost klogd:  disk 4, o:1, dev:sdk1
Jun  1 22:44:10 localhost klogd:  disk 5, o:1, dev:sdg1
Jun  1 22:44:10 localhost klogd:  disk 6, o:1, dev:sda1
Jun  1 22:44:10 localhost klogd: RAID5 conf printout:
Jun  1 22:44:10 localhost klogd:  --- rd:7 wd:6
Jun  1 22:44:10 localhost klogd:  disk 1, o:1, dev:sdl1
Jun  1 22:44:10 localhost klogd:  disk 2, o:1, dev:sdh1
Jun  1 22:44:10 localhost klogd:  disk 3, o:1, dev:sdj1
Jun  1 22:44:10 localhost klogd:  disk 4, o:1, dev:sdk1
Jun  1 22:44:10 localhost klogd:  disk 5, o:1, dev:sdg1
Jun  1 22:44:10 localhost klogd:  disk 6, o:1, dev:sda1
Jun  1 22:44:10 localhost klogd: RAID5 conf printout:
Jun  1 22:44:10 localhost klogd:  --- rd:7 wd:6
Jun  1 22:44:10 localhost klogd:  disk 0, o:1, dev:sdb1
Jun  1 22:44:10 localhost klogd:  disk 1, o:1, dev:sdl1
Jun  1 22:44:10 localhost klogd:  disk 2, o:1, dev:sdh1
Jun  1 22:44:10 localhost klogd:  disk 3, o:1, dev:sdj1
Jun  1 22:44:10 localhost klogd:  disk 4, o:1, dev:sdk1
Jun  1 22:44:10 localhost klogd:  disk 5, o:1, dev:sdg1
Jun  1 22:44:10 localhost klogd:  disk 6, o:1, dev:sda1
Jun  1 22:44:10 localhost klogd: md: recovery of RAID array md0
Jun  1 22:44:10 localhost klogd: md: unbind<sdi1>
Jun  1 22:44:10 localhost klogd: md: minimum _guaranteed_  speed: 1000
KB/sec/disk.
Jun  1 22:44:10 localhost klogd: md: using maximum available idle IO
bandwidth (but not more than 200000 KB/sec) for recovery.
Jun  1 22:44:10 localhost klogd: md: using 128k window, over a total of
976759936 blocks.
Jun  1 22:44:10 localhost klogd: md: export_rdev(sdi1)

[root@localhost ~]# more /proc/mdstat 
Personalities : [raid6] [raid5] [raid4] 
md0 : active raid5 sdb1[7] sda1[6] sdg1[5] sdk1[4] sdj1[3] sdh1[2] sdl1[1]
      5860559616 blocks level 5, 64k chunk, algorithm 2 [7/6] [_UUUUUU]
      [=====>...............]  recovery = 27.5% (269352320/976759936)
finish=276.2min speed=42686K/sec

// surface error on RAID drive while recovery:

Jun  2 03:58:59 localhost klogd: ata1.00: exception Emask 0x0 SAct 0xffff
SErr 0x0 action 0x0
Jun  2 03:59:49 localhost klogd: ata1.00: irq_stat 0x40000008
Jun  2 03:59:49 localhost klogd: ata1.00: cmd
60/08:58:3f:bd:b8/00:00:6b:00:00/40 tag 11 ncq 4096 in
Jun  2 03:59:49 localhost klogd:          res
41/40:08:3f:bd:b8/8c:00:6b:00:00/00 Emask 0x409 (media error) <F>
Jun  2 03:59:49 localhost klogd: ata1.00: status: { DRDY ERR }
Jun  2 03:59:49 localhost klogd: ata1.00: error: { UNC }
Jun  2 03:59:49 localhost klogd: ata1.00: configured for UDMA/133
Jun  2 03:59:49 localhost klogd: ata1: EH complete
Jun  2 03:59:49 localhost klogd: sd 0:0:0:0: [sda] 2930277168 512-byte
hardware sectors: (1.50 TB/1.36 TiB)
Jun  2 03:59:49 localhost klogd: sd 0:0:0:0: [sda] Write Protect is off
Jun  2 03:59:49 localhost klogd: sd 0:0:0:0: [sda] Write cache: enabled,
read cache: enabled, doesn't support DPO or FUA
Jun  2 03:59:49 localhost klogd: ata1.00: exception Emask 0x0 SAct 0x3ffc
SErr 0x0 action 0x0
Jun  2 03:59:49 localhost klogd: ata1.00: irq_stat 0x40000008
Jun  2 03:59:49 localhost klogd: ata1.00: cmd
60/08:20:3f:bd:b8/00:00:6b:00:00/40 tag 4 ncq 4096 in
Jun  2 03:59:49 localhost klogd:          res
41/40:08:3f:bd:b8/28:00:6b:00:00/00 Emask 0x409 (media error) <F>
Jun  2 03:59:49 localhost klogd: ata1.00: status: { DRDY ERR }
Jun  2 03:59:49 localhost klogd: ata1.00: error: { UNC }
Jun  2 03:59:49 localhost klogd: ata1.00: configured for UDMA/133
Jun  2 03:59:49 localhost klogd: ata1: EH complete
Jun  2 03:59:49 localhost klogd: sd 0:0:0:0: [sda] 2930277168 512-byte
hardware sectors: (1.50 TB/1.36 TiB)
Jun  2 03:59:49 localhost klogd: sd 0:0:0:0: [sda] Write Protect is off
Jun  2 03:59:49 localhost klogd: sd 0:0:0:0: [sda] Write cache: enabled,
read cache: enabled, doesn't support DPO or FUA
...
Jun  2 03:59:49 localhost klogd: raid5:md0: read error not correctable
(sector 1807269136 on sda1).
Jun  2 03:59:49 localhost klogd: raid5:md0: read error not correctable
(sector 1807269144 on sda1).
Jun  2 03:59:49 localhost klogd: raid5:md0: read error not correctable
(sector 1807269152 on sda1).
Jun  2 03:59:49 localhost klogd: raid5:md0: read error not correctable
(sector 1807269160 on sda1).
Jun  2 03:59:49 localhost klogd: raid5:md0: read error not correctable
(sector 1807269168 on sda1).
Jun  2 03:59:49 localhost klogd: raid5:md0: read error not correctable
(sector 1807269176 on sda1).
Jun  2 03:59:49 localhost klogd: raid5:md0: read error not correctable
(sector 1807269184 on sda1).
Jun  2 03:59:49 localhost klogd: raid5:md0: read error not correctable
(sector 1807269192 on sda1).
Jun  2 03:59:49 localhost klogd: raid5:md0: read error not correctable
(sector 1807269200 on sda1).
Jun  2 03:59:49 localhost klogd: raid5:md0: read error not correctable
(sector 1807269208 on sda1).
Jun  2 03:59:49 localhost klogd: ata1: EH complete
Jun  2 03:59:49 localhost klogd: sd 0:0:0:0: [sda] 2930277168 512-byte
hardware sectors: (1.50 TB/1.36 TiB)
Jun  2 03:59:49 localhost klogd: sd 0:0:0:0: [sda] Write Protect is off
Jun  2 03:59:49 localhost klogd: sd 0:0:0:0: [sda] Write cache: enabled,
read cache: enabled, doesn't support DPO or FUA
Jun  2 03:59:49 localhost klogd: RAID5 conf printout:
Jun  2 03:59:49 localhost klogd:  --- rd:7 wd:5
Jun  2 03:59:49 localhost klogd:  disk 0, o:1, dev:sdb1
Jun  2 03:59:49 localhost klogd:  disk 1, o:1, dev:sdl1
Jun  2 03:59:49 localhost klogd:  disk 2, o:1, dev:sdh1
Jun  2 03:59:49 localhost klogd:  disk 3, o:1, dev:sdj1
Jun  2 03:59:49 localhost klogd:  disk 4, o:1, dev:sdk1
Jun  2 03:59:49 localhost klogd:  disk 5, o:1, dev:sdg1
Jun  2 03:59:49 localhost klogd:  disk 6, o:0, dev:sda1
Jun  2 03:59:49 localhost klogd: RAID5 conf printout:
Jun  2 03:59:49 localhost klogd:  --- rd:7 wd:5
Jun  2 03:59:49 localhost klogd:  disk 1, o:1, dev:sdl1
Jun  2 03:59:49 localhost klogd:  disk 2, o:1, dev:sdh1
Jun  2 03:59:49 localhost klogd:  disk 3, o:1, dev:sdj1
Jun  2 03:59:50 localhost klogd:  disk 4, o:1, dev:sdk1
Jun  2 03:59:50 localhost klogd:  disk 5, o:1, dev:sdg1
Jun  2 03:59:50 localhost klogd:  disk 6, o:0, dev:sda1
Jun  2 03:59:50 localhost klogd: RAID5 conf printout:
Jun  2 03:59:50 localhost klogd:  --- rd:7 wd:5
Jun  2 03:59:50 localhost klogd:  disk 1, o:1, dev:sdl1
Jun  2 03:59:50 localhost klogd:  disk 2, o:1, dev:sdh1
Jun  2 03:59:50 localhost klogd:  disk 3, o:1, dev:sdj1
Jun  2 03:59:50 localhost klogd:  disk 4, o:1, dev:sdk1
Jun  2 03:59:50 localhost klogd:  disk 5, o:1, dev:sdg1
Jun  2 03:59:50 localhost klogd:  disk 6, o:0, dev:sda1
Jun  2 03:59:50 localhost klogd: RAID5 conf printout:
Jun  2 03:59:50 localhost klogd:  --- rd:7 wd:5
Jun  2 03:59:50 localhost klogd:  disk 1, o:1, dev:sdl1
Jun  2 03:59:50 localhost klogd:  disk 2, o:1, dev:sdh1
Jun  2 03:59:50 localhost klogd:  disk 3, o:1, dev:sdj1
Jun  2 03:59:50 localhost klogd:  disk 4, o:1, dev:sdk1
Jun  2 03:59:50 localhost klogd:  disk 5, o:1, dev:sdg1
Jun  2 04:26:17 localhost smartd[2502]: Device: /dev/sda, 34 Currently
unreadable (pending) sectors 
Jun  2 04:26:17 localhost smartd[2502]: Device: /dev/sda, 34 Offline
uncorrectable sectors 

// md0 is now down. But hey, still got the old drive, so just add it again:

[root@localhost ~]# mdadm /dev/md0 --add /dev/sdi1

Jun  2 09:11:49 localhost klogd: md: bind<sdi1>

// it's just added as a SPARE! HELP!!! reboot always helps..

[root@localhost ~]# reboot
[root@localhost log]# mdadm -E /dev/sd[bagkjhli]1
/dev/sda1:
          Magic : a92b4efc
        Version : 0.90.00
           UUID : 15401f4b:391c2538:89022bfa:d48f439f
  Creation Time : Sun Nov  2 13:21:54 2008
     Raid Level : raid5
  Used Dev Size : 976759936 (931.51 GiB 1000.20 GB)
     Array Size : 5860559616 (5589.07 GiB 6001.21 GB)
   Raid Devices : 7
  Total Devices : 7
Preferred Minor : 0

    Update Time : Mon Jun  1 22:44:10 2009
          State : clean
 Active Devices : 6
Working Devices : 7
 Failed Devices : 0
  Spare Devices : 1
       Checksum : 22d364f3 - correct
         Events : 2599984

         Layout : left-symmetric
     Chunk Size : 64K

      Number   Major   Minor   RaidDevice State
this     6       8        1        6      active sync   /dev/sda1

   0     0       0        0        0      removed
   1     1       8      177        1      active sync   /dev/sdl1
   2     2       8      113        2      active sync   /dev/sdh1
   3     3       8      145        3      active sync   /dev/sdj1
   4     4       8      161        4      active sync   /dev/sdk1
   5     5       8       97        5      active sync   /dev/sdg1
   6     6       8        1        6      active sync   /dev/sda1
   7     7       8       17        7      spare   /dev/sdb1
/dev/sdb1:
          Magic : a92b4efc
        Version : 0.90.00
           UUID : 15401f4b:391c2538:89022bfa:d48f439f
  Creation Time : Sun Nov  2 13:21:54 2008
     Raid Level : raid5
  Used Dev Size : 976759936 (931.51 GiB 1000.20 GB)
     Array Size : 5860559616 (5589.07 GiB 6001.21 GB)
   Raid Devices : 7
  Total Devices : 8
Preferred Minor : 0

    Update Time : Tue Jun  2 09:11:49 2009
          State : clean
 Active Devices : 5
Working Devices : 7
 Failed Devices : 1
  Spare Devices : 2
       Checksum : 22d3f8dd - correct
         Events : 2599992

         Layout : left-symmetric
     Chunk Size : 64K

      Number   Major   Minor   RaidDevice State
this     8       8       17        8      spare   /dev/sdb1

   0     0       0        0        0      removed
   1     1       8      177        1      active sync   /dev/sdl1
   2     2       8      113        2      active sync   /dev/sdh1
   3     3       8      145        3      active sync   /dev/sdj1
   4     4       8      161        4      active sync   /dev/sdk1
   5     5       8       97        5      active sync   /dev/sdg1
   6     6       0        0        6      faulty removed
   7     7       8      129        7      spare   /dev/sdi1
   8     8       8       17        8      spare   /dev/sdb1
/dev/sdg1:
          Magic : a92b4efc
        Version : 0.90.00
           UUID : 15401f4b:391c2538:89022bfa:d48f439f
  Creation Time : Sun Nov  2 13:21:54 2008
     Raid Level : raid5
  Used Dev Size : 976759936 (931.51 GiB 1000.20 GB)
     Array Size : 5860559616 (5589.07 GiB 6001.21 GB)
   Raid Devices : 7
  Total Devices : 8
Preferred Minor : 0

    Update Time : Tue Jun  2 09:11:49 2009
          State : clean
 Active Devices : 5
Working Devices : 7
 Failed Devices : 1
  Spare Devices : 2
       Checksum : 22d3f92d - correct
         Events : 2599992

         Layout : left-symmetric
     Chunk Size : 64K

      Number   Major   Minor   RaidDevice State
this     5       8       97        5      active sync   /dev/sdg1

   0     0       0        0        0      removed
   1     1       8      177        1      active sync   /dev/sdl1
   2     2       8      113        2      active sync   /dev/sdh1
   3     3       8      145        3      active sync   /dev/sdj1
   4     4       8      161        4      active sync   /dev/sdk1
   5     5       8       97        5      active sync   /dev/sdg1
   6     6       0        0        6      faulty removed
   7     7       8      129        7      spare   /dev/sdi1
   8     8       8       17        8      spare   /dev/sdb1
/dev/sdh1:
          Magic : a92b4efc
        Version : 0.90.00
           UUID : 15401f4b:391c2538:89022bfa:d48f439f
  Creation Time : Sun Nov  2 13:21:54 2008
     Raid Level : raid5
  Used Dev Size : 976759936 (931.51 GiB 1000.20 GB)
     Array Size : 5860559616 (5589.07 GiB 6001.21 GB)
   Raid Devices : 7
  Total Devices : 8
Preferred Minor : 0

    Update Time : Tue Jun  2 09:11:49 2009
          State : clean
 Active Devices : 5
Working Devices : 7
 Failed Devices : 1
  Spare Devices : 2
       Checksum : 22d3f937 - correct
         Events : 2599992

         Layout : left-symmetric
     Chunk Size : 64K

      Number   Major   Minor   RaidDevice State
this     2       8      113        2      active sync   /dev/sdh1

   0     0       0        0        0      removed
   1     1       8      177        1      active sync   /dev/sdl1
   2     2       8      113        2      active sync   /dev/sdh1
   3     3       8      145        3      active sync   /dev/sdj1
   4     4       8      161        4      active sync   /dev/sdk1
   5     5       8       97        5      active sync   /dev/sdg1
   6     6       0        0        6      faulty removed
   7     7       8      129        7      spare   /dev/sdi1
   8     8       8       17        8      spare   /dev/sdb1
/dev/sdi1:
          Magic : a92b4efc
        Version : 0.90.00
           UUID : 15401f4b:391c2538:89022bfa:d48f439f
  Creation Time : Sun Nov  2 13:21:54 2008
     Raid Level : raid5
  Used Dev Size : 976759936 (931.51 GiB 1000.20 GB)
     Array Size : 5860559616 (5589.07 GiB 6001.21 GB)
   Raid Devices : 7
  Total Devices : 8
Preferred Minor : 0

    Update Time : Tue Jun  2 09:11:49 2009
          State : clean
 Active Devices : 5
Working Devices : 7
 Failed Devices : 1
  Spare Devices : 2
       Checksum : 22d3f94b - correct
         Events : 2599992

         Layout : left-symmetric
     Chunk Size : 64K

      Number   Major   Minor   RaidDevice State
this     7       8      129        7      spare   /dev/sdi1

   0     0       0        0        0      removed
   1     1       8      177        1      active sync   /dev/sdl1
   2     2       8      113        2      active sync   /dev/sdh1
   3     3       8      145        3      active sync   /dev/sdj1
   4     4       8      161        4      active sync   /dev/sdk1
   5     5       8       97        5      active sync   /dev/sdg1
   6     6       0        0        6      faulty removed
   7     7       8      129        7      spare   /dev/sdi1
   8     8       8       17        8      spare   /dev/sdb1
/dev/sdj1:
          Magic : a92b4efc
        Version : 0.90.00
           UUID : 15401f4b:391c2538:89022bfa:d48f439f
  Creation Time : Sun Nov  2 13:21:54 2008
     Raid Level : raid5
  Used Dev Size : 976759936 (931.51 GiB 1000.20 GB)
     Array Size : 5860559616 (5589.07 GiB 6001.21 GB)
   Raid Devices : 7
  Total Devices : 8
Preferred Minor : 0

    Update Time : Tue Jun  2 09:11:49 2009
          State : clean
 Active Devices : 5
Working Devices : 7
 Failed Devices : 1
  Spare Devices : 2
       Checksum : 22d3f959 - correct
         Events : 2599992

         Layout : left-symmetric
     Chunk Size : 64K

      Number   Major   Minor   RaidDevice State
this     3       8      145        3      active sync   /dev/sdj1

   0     0       0        0        0      removed
   1     1       8      177        1      active sync   /dev/sdl1
   2     2       8      113        2      active sync   /dev/sdh1
   3     3       8      145        3      active sync   /dev/sdj1
   4     4       8      161        4      active sync   /dev/sdk1
   5     5       8       97        5      active sync   /dev/sdg1
   6     6       0        0        6      faulty removed
   7     7       8      129        7      spare   /dev/sdi1
   8     8       8       17        8      spare   /dev/sdb1
/dev/sdk1:
          Magic : a92b4efc
        Version : 0.90.00
           UUID : 15401f4b:391c2538:89022bfa:d48f439f
  Creation Time : Sun Nov  2 13:21:54 2008
     Raid Level : raid5
  Used Dev Size : 976759936 (931.51 GiB 1000.20 GB)
     Array Size : 5860559616 (5589.07 GiB 6001.21 GB)
   Raid Devices : 7
  Total Devices : 8
Preferred Minor : 0

    Update Time : Tue Jun  2 09:11:49 2009
          State : clean
 Active Devices : 5
Working Devices : 7
 Failed Devices : 1
  Spare Devices : 2
       Checksum : 22d3f96b - correct
         Events : 2599992

         Layout : left-symmetric
     Chunk Size : 64K

      Number   Major   Minor   RaidDevice State
this     4       8      161        4      active sync   /dev/sdk1

   0     0       0        0        0      removed
   1     1       8      177        1      active sync   /dev/sdl1
   2     2       8      113        2      active sync   /dev/sdh1
   3     3       8      145        3      active sync   /dev/sdj1
   4     4       8      161        4      active sync   /dev/sdk1
   5     5       8       97        5      active sync   /dev/sdg1
   6     6       0        0        6      faulty removed
   7     7       8      129        7      spare   /dev/sdi1
   8     8       8       17        8      spare   /dev/sdb1
/dev/sdl1:
          Magic : a92b4efc
        Version : 0.90.00
           UUID : 15401f4b:391c2538:89022bfa:d48f439f
  Creation Time : Sun Nov  2 13:21:54 2008
     Raid Level : raid5
  Used Dev Size : 976759936 (931.51 GiB 1000.20 GB)
     Array Size : 5860559616 (5589.07 GiB 6001.21 GB)
   Raid Devices : 7
  Total Devices : 8
Preferred Minor : 0

    Update Time : Tue Jun  2 09:11:49 2009
          State : clean
 Active Devices : 5
Working Devices : 7
 Failed Devices : 1
  Spare Devices : 2
       Checksum : 22d3f975 - correct
         Events : 2599992

         Layout : left-symmetric
     Chunk Size : 64K

      Number   Major   Minor   RaidDevice State
this     1       8      177        1      active sync   /dev/sdl1

   0     0       0        0        0      removed
   1     1       8      177        1      active sync   /dev/sdl1
   2     2       8      113        2      active sync   /dev/sdh1
   3     3       8      145        3      active sync   /dev/sdj1
   4     4       8      161        4      active sync   /dev/sdk1
   5     5       8       97        5      active sync   /dev/sdg1
   6     6       0        0        6      faulty removed
   7     7       8      129        7      spare   /dev/sdi1
   8     8       8       17        8      spare   /dev/sdb1

the old RAID configuration was:

disc 0: sdi1 <- is now disc 7 and SPARE
disc 1: sdl1
disc 2: sdh1
disc 3: sdj1
disc 4: sdk1
disc 5: sdg1
disc 6: sda1 <- is now faulty removed

[root@localhost log]# mdadm --assemble --force /dev/md0 /dev/sd[ilhjkgab]1
mdadm: /dev/md/0 assembled from 5 drives and 2 spares - not enough to start
the array.
[root@localhost log]# cat /proc/mdstat 
Personalities : 
md0 : inactive sdl1[1](S) sdb1[8](S) sdi1[7](S) sda1[6](S) sdg1[5](S)
sdk1[4](S) sdj1[3](S) sdh1[2](S)
      8790840960 blocks


On large arrays this may happen a lot: A bad drive is first discovered
during maintenance operations when it's too late. Maybe an option to add a
redundant drive in a fail-save way would be a good idea to add to md
sevices.

Please tell me if you see any solution to the problems below.

1. Is it possible to reassign /dev/sdi1 as disc 0 and access the RAID as is
was before the restore attempt?

2. Is it possible to reassign /dev/sda1 as disc 6 and backup the still
readable data on the RAID?

3. I guess more then 90% of data was written to /dev/sdb1 in the restore
attempt. Is it possble to use /dev/sdb1 as disc 7 to access the RAID?

Thank you for looking at the problem
Alexander
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